FIELD OF THE INVENTION
[0002] The present invention relates to the field of motor vehicle headlamps with internal
reflectors contained within a headlamp housing and lens, and mechanisms for damping
fluttering of the reflectors. The present invention also relates to a linkage that
synchronizes the aim of a high beam reflector with a low beam reflector while also
providing damping for both reflectors to stop them from visibly shaking or fluttering
the light beam under vibration in actual use.
BACKGROUND
[0003] Vehicle headlamps designed with two independent reflectors, typically one used for
the low beam and one used for the high beam, are also typically aim adjusted from
a single adjustment location outside the headlamp. A linkage bracket can be used inside
the headlamp to connect the low and high beam reflectors and synchronize aim. However,
preventing reflector flutter under vibration can be difficult in this situation, due
in part to the mass of each reflector independently being suspended about separate
pivot points, in addition to other reflector design variables.
[0004] As such, there is a need for a linkage bracket to connect and synchronize independently
pivoting reflectors for aiming, while also providing damping to prevent beam flutter
for one or both reflectors during vibration in actual use. There is also a need for
an improved mechanism for providing damping to prevent beam flutter in individual
reflectors during vibration in actual use.
SUMMARY
[0005] Disclosed is a reflector damper bracket comprising a link damper, and a link bracket
in frictional sliding engagement with the link damper. The link bracket includes at
least one ball adapted for attachment to at least one reflector, and the link damper
includes a post adapted for attachment to a headlamp housing.
[0006] It will be understood by those skilled in the art that one or more aspects of this
invention can meet certain objectives, while one or more other aspects can lead to
certain other objectives. Other objects, features, benefits and advantages of the
present invention will be apparent in this summary and descriptions of the disclosed
embodiment, and will be readily apparent to those skilled in the art. Such objects,
features, benefits and advantages will be apparent from the above as taken in conjunction
with the accompanying figures and all reasonable inferences to be drawn therefrom.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007]
FIG. 1 is a side view cross section of a headlamp that includes one embodiment of
a reflector damper bracket in accordance with the invention.
FIG. 2 is a perspective view cross section of a headlamp that includes the reflector
damper bracket of FIG. 1.
FIG. 3 and FIG. 4 are exploded perspectives view of the reflector damper bracket of
FIG. 1.
FIG. 5A is a bottom view of the reflector damper bracket of FIG. 1.
FIG. 5B is a side view of the reflector damper bracket of FIG. 1.
FIG. 5C is a top view of the reflector damper bracket of FIG. 1.
FIG. 6A is a perspective view and FIG. 6B is a cross section of the reflector damper
bracket of FIG. 1.
FIG. 7 is an enlarged perspective view of the reflector damper bracket of FIG. 1.
FIG. 8 is a partial perspective view of the rear of a reflector with another embodiment
of a reflector damper bracket in accordance with the invention.
FIG. 9 is a partial cross sectional view through the housing boss, link damper, link
bracket, and ball socket shown in FIG. 8.
DETAILED DESCRIPTION
[0008] The embodiment of a reflector damper bracket 200 shown in FIG. 1 and FIG. 2 consists
of a link bracket 6 and a link damper 7 located inside a headlamp assembly 100. The
link bracket 6 is connected to an upper reflector 2 and a lower reflector 3 using
ball sockets 5 located at each end of the link bracket 6. The upper reflector 2 and
lower reflector 3 also have additional ball sockets 5 for fixed pivots arranged in
a manner such that when the adjuster 4 moves right or left, as shown in FIG. 1, the
link bracket 6 moves up and down, synchronizing the rotation of upper reflector 2
and lower reflector 3 about their respective fixed pivots.
[0009] The link bracket 6 has an up and down sliding fit with the link damper 7 which is
attached to the headlamp housing 1 using a post 12 that is inserted into a boss hole
1a inside a headlamp housing boss 1b.
[0010] FIGS. 3 and FIG. 4 show the separate parts of the link damper bracket 200 before
they are put together. The link bracket 6 includes spaced apart ball pivots 8 at each
end, a body 10 and a plate 11. The link damper 7 includes the post 12 extending from
a channel or C-shaped guide 15, and a slot 9. The slot 9 of the link bracket 7 receives
the plate 11 of the link bracket 6 when the two parts are assembled in the direction
of the arrow as shown in FIG. 4, and creates a tight sliding friction fit. Once assembled,
the link damper 7 remains attached to the link bracket 6 in the desired position,
due to the friction fit.
[0011] FIGS. 5A, 5B and 5C show several views of the link damper bracket 200 with the link
bracket 6 and link damper 7 assembled together and ready for assembly to the headlamp
100. Both parts may be molded from any number of plastics suitable for the headlamp
such as, but not limited to, Polycarbonate, PP or Nylon.
[0012] FIGS. 6A and 6B show the detail of the sliding friction fit between the link bracket
plate 11 and the link damper slot 9. The inside of the slot 9 can be tapered to a
desired angle A to aid in creating a friction fit. The slot 9 and plate 11 can be
nearly any shape or angle to suit the application, or can be reversed so that the
slot 9 is formed in the link bracket 6 and the plate 11 is formed in the link damper
7, without departing from the invention. To prevent unwanted beam flutter during vibration,
a minimum friction force in the direction of arrows FD is needed. To allow adjustment
function and prevent undue stress on components, a maximum friction force FD is also
needed. The interference fit between the plate 11 and slot 9 creates a clamp force
F. Angle A (see FIG. 6B) of plate edge 25 (see FIG. 7) between the plate 11 and slot
9 creates a wedge fit which helps to achieve a desired friction force FD, without
the need for excessive interference between parts and related material stress. Therefore
a desired friction force FD can be achieved at relatively low clamp forces F.
[0013] As illustrated in FIG. 8, one reflector is shown mounted by four connections. One
is a reflector adjuster 31 shown in the upper left corner of FIG. 8. The adjuster
31, when its top mounted gear is turned, results in reverse or forward movement of
a plunger 33 pivotally connected to the reflector 3. This in turn results in the back
or forth movement of the top of the reflector 3. The reflector 3 is also mounted at
two fixed pivot points 35 and 37, at the left lower corner and right lower corner
of the reflector 3. Thus, the back and forth movement of the top of the reflector
3 by the adjuster 31 results in the tilting up or down of the reflector 3.
[0014] Because of the mass of the reflector 3, as described above, jolting or vibrating
of a vehicle in which the reflector 3 is mounted can result in the fluttering of the
reflector 3 and its included light beam. In order to limit this fluttering, the reflector
3 is also connected to a link damper 7 according to this disclosure. More particularly,
an embodiment of a link bracket 6a is shown in FIG. 9. The link bracket 6a is identical
to the link bracket 6, except now it has a single ball pivot 8a. As described above,
the link damper 7 includes a slot 9. The slot 9 of the link bracket 7 receives a plate
11a of the link bracket 6a when the two parts are assembled in the direction of the
arrow as shown in FIG. 4, and creates a sliding friction fit. Once assembled, the
link damper 7 remains attached to the link bracket 6a in the desired position, due
to the friction fit.
[0015] As a result of the mounting of the link bracket 6a in the link damper 7, movement
of the reflector 3 and the link bracket 6a in a vertical direction, as shown in FIGS.
8 and 9, is dampened by the link damper 7. In other embodiments (not shown), where
other pivot mountings of the reflector may be used, the link bracket 6a and link damper
7 can be rotated ninety degrees relative to the housing boss 1b so that the reflector
3 can also be dampened when there is movement in a horizontal direction. In still
other embodiments (not shown), more than one link damper and one link bracket can
be used with each reflector in order to provide damping in both a vertical and horizontal
direction, if desired.
[0016] Although the invention has been herein described in what is perceived to be the most
practical and preferred embodiments, it is to be understood that the invention is
not intended to be limited to the specific embodiments set forth above. Rather, it
is recognized that modifications may be made by one of skill in the art of the invention
without departing from the spirit or intent of the invention and, therefore, the invention
is to be taken as including all reasonable equivalents to the subject matter of the
appended claims and the description of the invention herein.
1. A reflector damper bracket comprising:
- a link damper, and
- a link bracket in frictional sliding engagement with the link damper, the link bracket
including at least one ball adapted for attachment to at least one reflector, the
link damper including a post adapted for attachment to a headlamp housing.
2. A reflector damper bracket in accordance with Claim 1 wherein one of the link bracket
and the link damper includes a plate and the other includes a C-shaped portion in
frictional sliding engagement with the plate.
3. A reflector damper bracket in accordance with Claim 2 wherein the link bracket includes
a plate and the link damper includes a C-shaped portion in frictional sliding engagement
with the plate.
4. A reflector damper bracket in accordance with Claim 2 wherein the plate has spaced
apart parallel edges.
5. A reflector damper bracket in accordance with Claim 4 wherein each of the spaced apart
parallel edges has a wedge shape.
6. A reflector damper bracket in accordance with Claim 1 wherein the link bracket includes
at least two spaced apart balls, each of which is adapted for attachment to at least
one reflector.
7. A reflector damper bracket comprising:
- a link damper, and
- a link bracket in frictional sliding engagement with the link damper, the link bracket
including a plate having two spaced apart parallel edges, and each of the spaced apart
parallel edges has a wedge shape, and at least two spaced apart balls attached to
the plate, each ball being adapted for attachment to at least one reflector, the link
damper including a post adapted for attachment to a headlamp housing, and the link
damper including a C-shaped portion in frictional sliding engagement with the plate.